Method of and mold for casting vitreous water closet bowls



Sept. 14, 1948. J. w. PIESLAK El'AL 2,449,249

METHOD OF AND MOLDS FOR CASTING VITREOUS WATER CLOSET BOWLS Filed Nov. 15, 1944 I a Sheets-Sheet 1 Sept. 14, 1948. ,J. w. PlESLAK ETAL 2,449,249

' METHOD OF AND HOLDS FOR CASTING VITREOUS WATER CLOSET BOWLS Filed Nov. 15, 1944 3 Sheets-Sheet 2 P 1943- J. w. PIESLAK ETAL 2,449,249

METHOD OF AND MOLDS FOR CASTING VITREOUS WAT OSET BOWLS Filed NOV. 15, 1944 3 Sheets-Sheet 3 Am I c- 4 wow view Patented Sept. 14, 1948 METHOD OF AND MOLD FOR CASTING YITREOUS WATER CLOSET BOWLS Joseph W. Pieslak and Raymond E, Crane, Kittanning, Pa.

Application November 15, 1944, Serial No. 563,532

9 Claims. (01. 25-129) 'This invention relates to hollow vitreous castings, such as water closet bowls, and the casting thereof from liquid clay slip.

Objects of the present invention are to provid for casting such an article in a new and improved manner so as to provide a new and improved product wherein joints are obviated in the bowl proper, the tr-apway and other parts of the casting; to enable the formation of the bowl and its associated trapway in the form of a single integral casting free from joints; to reduce the parts of the mold to the minimum number of parts; and to simplify the assembly and the taking apart of the mold and otherwise simplifya ing and improving the production of vitreous water closet bowls. r

With these and other objects in view, the present invention consists in the combination and arrangement of parts as will be hereinafter more fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims,it being understood that changes in the form, proportion, size and minor details may be made, within the scope of the claims, without departing from the spirit orsacrificing any of the advantages of the invention.

In the drawings Figure 1 is a vertical longitudinal sectional view of a water closet bowl mold of the present invention and showing the bowl casting therein;

Figure 2 is a vertical cross sectional view on the line 2- -2 of Figure 1;

Figure 3 is a rear elevation of Figur 1 one. smaller scale;

Figure 4 is a fragmentary plan section on the line 4-4 of Figure 3;

Figure 5 is .a detailed vertical sectional view of the combined back and plug member of the bowl;

Figure 6 is a fragmentary vertical sectional view of a top portion of the mold and the contained casting, the top member of the mold be-' ing removed, and a flushing rimfitted to the top edge of the casting;

Figure 7 is a fragmentary'sectional view similar to Figure 1 and showing a modification;

Figure 8 is :a rear elevation of Figure Lon a smaller scale;

Figure 9 is a fragmentary plan section on the tom mold member and the upper side mold memher being removed, and showing a slab lying against the top of the flushing rim; and

'Figure 13 is an elevation of thecasting, on a place preparatory to removal. j

According to the embodiment of the present in- Vention as shown in the accompanyingidrawings,

the mold includes opposite duplicate upright wall members A and B, a base Wall member 0, and a. top wall member ID. The-inner face of each upi right mold wall member A and B is configured to define av part of thebowl, and upright sideportions of the downleg l of the trapway and the upleg 2 of the trapway. The base wall member C has its top iace configured in accordance with the desired configuration of the bottom ofthe casting andincludes an upstanding humpor ele vation 3', constituting in efiect a core whose topand side surfaces are shaped to define portions of the casting. it 1 The top wall member D of themold rests upon the top edges of the upright sidewall members A: and Band is provided with a depending projection or boss 4, which may be integral with the top or otherwise, extending downwardly within the space defined by the side wall members A and B and constituting: a, core whos exterior surface is configured to give'the desired shape to the inner surface of the bottom of the bowl and the inner uprightsurfaces thereof. The core 4 is spaced a suitable distance from the inner walls of the bowl portions of the side members A and B so astto receive therebetween th liquid'clay slip employed to =make the casting, as will be herein-afterexplained. -A pouring opening: 5 of suitable size and configuration, is provided through the'top draining the liquid clay slipfromthemold, the

bottom wall member C is provided with a drain opening 6 communicatingwith the bottom of the i downleg portion I of the casting.

In Figures 1 to 5, inclusive, it will be seen that the wall portions of the casting which separate the downleg I from the upleg 2 are deposited or formed on a partition 1 which is in thenature of aplug carried as a part of a mold back-Wall member 8 which is arcuate in shape in a hori-' zontal direction as best shown in Figure 4. i This back wall mold member rises from the base wall C and terminates short of the tops of the mold side wall members A and B, which sides are notched or cut away, as indicated at 9 to receive the arcuate mold back wall member 8. This combined plug and back wall member is provided with an outwardly and rearwardly directed portion ID, in theupper face Of-Which is; provided? a gutter H leading to a drain opening l2 formed through the back wall member 8 immediately above the plug portion 1. To produce the usual downwardly extending jet channel-l3, an upright groove or channel l-4, shown in Figure 4, is provided in the inner faces of the back parts of mold side wall members A andfl-B; and the memher 8.

In employing the mold qll'"t h;e-, present in-vene tion, as embodied in Figures 1, 2, 3, 4 and 5', for casting a water closet bowl, the upright side wall members A and B of the? mold are placed in an uprightrp'ositionupon. the base wall C, the combinedl plug and; back;wall member; 8 .:i-s then put. in place and supported! anatherbase wall-C, after. which these mold 'wallpartsare secured together by the. applicationiof suitable clam-ps1 or other fastening means not shown; The top. wall member Duisthen put in, place and supported upon the D ges of thewal'l, members A; and B with the-genre; itwithinstheabowledefining wall portions oftrthez-wallprnaembersiA, and B. Liquid clay slip is;them.pouredhthroughgthe"opening 5 in the Qpr-Dj llntflzallluof; 1 the spaces betweenthe severalportions. of; thesmold. wall. have become filled with the casti mgmmaterial, Asrusu-al, the mold wall memberdare'emadeof. plaster of-Paris or other suitable; waten-absorbingmaterial. so that water w ilklbe; absorbed-1 thereby from. that portion of me -liquid, cla slip-- in, Contact with and. adjacent toz the mold parts-to theend thatliquid clayslip wilt-adheregto the mold parts and thus build upahol'lowx castin 1ofrrth x fieuw o o t emtehiomofithemolda It. will of course be understood that the liquid clay slip will entirelyfillthe-tspacel-betweenr the. cooperating parts. or the mold, and that... only potion, thereotwill. ad+ hetertoithe. mold walls andbecome hardenedrsuf flcierrtlyuto;takeson the;: desired configuration, Whenva desired-bowl wali thickness. has-:been. de- DZOS ed collected; upon vthe mold walls. whichconditionuis determined. by. experience, 7 the. .slip: material; which; remains liquid. is.- discharged or: drawn fiITQmv the, mold throughz. discharge openinggltand t2; thus leaving; a hollow.- casting ofcarconfiguratienvdefined by the=mo1d walls,

' ltiwlll; be explaineckthat preparatory-to. pouringath'ecastingimatcrial into the mold, the drain ope 'ng itfi Zilfldzfl 2 I should-- be plugged: and closed imanynsuit'able; manner; such; plugs, subsequently beinga-removedwhem it is desired to discharge. or drain. materia-Lirom the-interior of; the mold. It; wi1 f=,::course;:.be.-understood that the mold maybe tilted; invertedor otherwisefmanipulated togiacili-tatetheidraining of the-liquid castinggmaterial fromtheimolda suitable length of time should. lapse betweeni the peu-ring ofq the liquid acastisng r-naterial and:

the. removal-10f the .rnol-dywa-ll; members; from the casting in order to permitgof-i sufiioient -n-oisture' being absorbed from the eastingby theiwal-lsef the -mold u-ntil' the.- casting Y has: become hard; enough;- to perm-ithaln-d-li ng; withoutbreakage;-

Wherr, ;the .;castihg; has hardened. .ito the: desired extent the tp wall member 'Dshoul-dlbe removed. upwardly; th Ehexposing the inside of :thercasta bowl: and the Mpper; edge. thereon.

4 as shown in Figure 6, any ordinary or preferred form of flushing rim I5 cast from liquefied clay slip should be placed in position on the top edge of the bowl and secured in place by means of the usual coating of sticking clay applied to either the edge of the bowl or the rim, or both.

When the rim has hardened sufiiciently and a satisfiactory'. adherencehasi taken place between the rim and the top edge of the casting, the mold is turned down so as to rest upon one of its side wall members, the mold being shown in this positioninFi-gurell with one side wall memberB resting upon some suitable support. The back wall member 8 and .plug 1 are then removed. The next step is to remove the bottom mold'wall member C horizontally, the casting being supported, within the side mold wall members A and B. After removing the bottom memher 0', the uppermost side wall member, A in the gether; wtih the side 'mol-d' wal1=.member B and.

the slab l6-are turned. to the? positionshown: in Figure 1 3 so as to; support the .castingonthe rim l5 which would in. turn be supported-upon the bat or slab. I64. The moldsidewall member B, which is now inan upright position, may-be removed horizontally away from thecasting. The casting: is: then permitted tocstan'd still. until it has dried toa satisfactory condition, after which; the casting issmooth-ed and finished to a condition such that it may be firedin a kiln. I From the foregoing description itwill be understood that. the bowl-proper together with its, trapway is an integral casting formed of. clayslip 4m and; withoutany joint-s whatsoever. There is, of.

course,.a.join t betweentheitop edge of the'boWl proper and. theflushing. rim,. but there are no,

joints inrthe bo'wl proper and-.i-n the trapway;

In; Figure 1- of the. drawings, the. discharge. opening. [I oil the bowlrleadinginto. the-1 trapway.

1 may be producedgby; applyingshellacto. the surface of the core Ill which is to define this. opening, the shellacoperatingto. prevent the accumulation. of; the casting materialon. this. coated surface portion. of the core. 4 If. desired, the shellac:

may be omitted..-and the casting material permitted to collect on the surface of: the care lwhere the. dischargeopening, should be, and thereafter the material may be removed. by cute ting before complete hardening of .the material.

In Figures 7, 8 and 9, there has-been showna.

slighLmodi-fication wherein the back mold wall membert is omitted, and the uprightsidemoldwall. members A- and B. extend in full. length from the base. tozthe. top ofthemold, the-meet.- ing edges. of thetmoldlwall members A i and :B,. at the back otthe mold beingprovided: with regis-; tered notches or recesses-.to.:-receive a. plug or:

partition] corresponding to'th-e plug on partition 1 of- Figure-la This .plluga hasa'rearward.

extensionllli andiatgutter ll similar to what. is shown in Figure 1. the'meeting edges-of the side; mold .wa-llr members A and B are provided with. registered notches.

lat-which allso: register with: the" open top;- of: the

inner.- end: oi the gutter..- :1 anddefineaad rainopeninggJS leading; into the gutter whereby; liquid clay; sl-i-p; maybe-:draineddrom. the iupleg portion Otherwise. the; em

2 and the jet passage l3. bodilmen-t of the invention; as. showrr Figures As well shown irrFigureB;

'l, 8 and 9,- isthe same as that shown in Figures 1 to 5, inclusive, and the method of removing the mold members is thesame as that described cfor, the embodiment shown in Figures. 1 to 5, inclusive. Q

Another embodiment ofthe invention has been shown in Figurelo of the drawing wherein the bottom wall member C .isprowidedwith an upwardly inclined opening or passage 20 to receive a plug 2| which is of a shape and dimension to extend upwardly beyond the top of the mold bottom wall C and define the lower wall of the upleg 2 and the inner wall of the downleg l. The opening Zll is so disposed and the plug 2| is soiconfigured that it may be withdrawn from between the adjacent walls of the legways l and 2 without damaging said walls preparatory to re moving the mold bottom wall C from the casting. Otherwise, the method of employing the mold of Figure is the same as that described for the other forms of the invention.

What we claim is:

liIn a mold for casting water closet bowls having a trapway including, an upleg and a downleg, the combination of a base mold wall having its. top configured to form the base of a bowl structure, upright side wall members supported on the base wall and configured to define sides of the bowl, atop mold wall member supported upon the top edges of the side mold wall members and having a depending core portion spaced from the upright s ide mold wall members to define the inner face of the bowl, and a plug member insertable and removable through a wall of the mold and having a portion disposed between the core and the base wall member said plug being spaced from the more to define an upleg between the core and the plug, and also spaced from the front and bottom walls of the mold to define a downleg between said parts, the bottom of the core, the front wall of the mold and the inner end portion of the plug being spaced to define an elbow passage between said parts and connecting the inner ends of the upleg and the downleg.

2. In a mold for casting water closet bowls having a trapway including an upleg and a downleg, the combination of a base mold wall having its top configured to form the base of a bowl structure, upright side wall members supported on the base wall and configured to define sides of the bowl, a top mold wall member supported upon the top edges of the side mold wall members and having a depending core portion spaced from the upright side mold wall members to define the inner face of the bowl, and a plug member insertible and removable through an upright wall of the mold and having a portion disposed between the core and the base wall member said plug being spaced from the core to define an upleg between the core and the plug, and also spaced from the front and bottom walls of the mold to define a downleg between said parts, the bottom of the core, the front wall of the mold and the inner end portion of the plug being spaced to define an elbow passage between said parts and connecting the inner ends of the upleg and the downleg.

3. In a mold for casting water closet bowls having a trapway including an upleg and a downleg, the combination of a. base mold wall having its top configured to form the base of a bowl structure, upright side wall members supported on the base wall and configured to define sides of the bowl, a top mold wall member supported upon the top edgesof the side mold wall members and having a depending: core portion spaced from the upright sidemold wall memberstodefine the [inner face of the bowl, and a plug member insertable and removable through the mold base wall member and having a portion disposed betweenthe core and the base wall member .to define the lower side of the. upleg and the inner side of the downleg ofthe trapway. 4. In a mold for casting'water closet bowls having a trapwayinoluding an upleg and a downleg, the combination of a base having itstop configured to form. the base of the bowl structure,

upright side members supported upon thebase and configured to'define sides of the bowl, a top resting upon the topof the sidemembers and having a depending core portionspaced from the upright side members to definethe inner face of the bowl, andaiplug lying in the spacebetween the base and the core and dividingsaid space into an upleg and a downleg of a trapway, said plug carrying aback member to define a portion of the back of the bowl, the upright side members beiing notched to receive the said back member. l

5. In a mold for casting water closet bowls having a trapway including an upleg andadownleg, the combination of a base mold well having a top configured to form the'baseqofthe bowl structure, upright side wall members resting upon the base wall and configured to define sides of the bowl, a top mold wall member resting: upon the tops of the side wall members and having a depending :core portion spaced from the upright side mold wall members to define the inner face of the bowl, the base mold wall member having an opening extending therethrough, and a removable plug extending through said opening and having a portion projecting into the space between the core and the base wall member and defining the lower wall of the upleg and the inner wall of the downleg of the trapwa; of the bowl.

6. The herein described method of casting water closet bowls comprising the steps of assem- Y bling opposite side mold members upon a base,

applying a top member having a depending core portion to define the inner wall of the bowl, inserting a plug member into the space between the core and the base member in position to define an upleg between the core and the plug and also to define a downleg between the front and bottom of the mold and the adjacent side of the plug, filling the spaces between the mold members with liquid clay slip and permitting the latter to adhere to the inner walls of the mold, removing surplus liquid clay slip from the mold, removing the top of the mold upwardly, turning the mold and supporting it on one side thereof, removing the plug member, removing the bottom member of the mold, removing the upper side mold member laterally from the casting, turning the casting and supporting it on the top thereof, and then removing the remaining mold side member.

'7. The herein described method of casting water closet bowls, comprising the steps of assembling opposite side mold members upon a base, applying a top member having a depending core portion to define the inner wall of the bowl, inserting a plug member into the space between the core and the base member in position to define an upleg between the core and the plug and also to define a downleg between thefront and bottom of the mold and the adjacent side of the plug, filling the spaces between the mold members with fliqwldw cl-ayl slip: and vpemlittiz'ng;the lattemto' adhere ta the: innerrwalls of" the-mold, remcvmgv surplus *clay' slip? from the: mold, removing; the top of: the mold upwardly, sticking a: prewast: flushing rim-upon the top ed'geof the casting; turning the meld L supporting iton one side thereof, .removing the plug member, ne moving; the bottom member of the-mold, .remov ing the uppersi'de mold imember laterallywfrom the-casting; turning the casting supporting it omithe' top"thereoli:v and then removing? the remaining mold side member;

a. lm'oldfor casting water eloset bowls having at trepwaly includingamupleg and adownleg; the" combination of atba'se' havmgits' top con-- figured to form the baseoflawbowl structure,- upright side members supported outhe base: and configuredto definezs ides of the: bowl,: 2; topsupported: upon the top edges of the side mold members and'havin-gr a depending core portion spaced firomthe' upright side: members to define thedrmer face of the bowl, and a; plug member insertable and removable: through a wa'll: of the moid and disposed betwcerrthe core. and the base member and inclined upwardly towards the closed front of the mold from the place: of insertion through: at Well. of the mold and termihating short of: the" closed front: wall of the meld, saidplugbeing spaced fromthe core to (lei-me anxupleg between-the core and plugv and allzswspacedifrumdhe trout and bottom walls of the moldi to define apdownle'g. between sai'dxparts',

thelbcttomsot the core, the front wal fi of. themold ends the inner end: portion of the plug" being spacedrto define: an elbow' passage between: said parts and. connectingythe innerverids e-i'the upleg v and the downfleg.

the innerface of the. bowl, and a; plug member insertableand removable through the upright back:v walll cf the mold and: disposed between the more and the basemember to" define the-lower side of the upleg andthe 'innerside 'of the clownieg of" the thapway: 1

JOSEPH: PIES-LAW. RAYMOND E. CRANE.

REFERENCES CITED The following references are of" recordlrr the fileoi this patent:

UNITED STATES PATENTS Number Name Date 1,156,085 Kirk Oct. 12, 1915 1,183,067 Hin May 16 1916- 

